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Sprinter hybrid electric and plug-in hybrid electric drive



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Sprinter hybrid electric and plug-in hybrid electric drive
Inner-city delivery vans do most of their work in areas where emissions are a major issue, therefore DaimlerChrysler is intensively developing alternative drive systems. Top right: ZF Sachs produces the strong Sprinter electric motor with 70 kW placed between combustion engine and transmission.
Sprinter info page
9/15/2006

Johnson Controls-Saft awarded program for lithium-ion batteries
A major automaker signed a letter of intent with Johnson Controls Saft Advanced Power Solutions (JCS) joint venture to produce a Li-Ion battery for a hybrid electric vehicle for evaluation, with production anticipated in the future. This would be the first JCS Lithium Ion hybrid battery plant in Europe, costing $15 to $20 million and be located in the eastern part of France.
JCS Li-ion High voltage battery for automotive application (pdf)
JCS plug-in hybrid and full hybrid Li-ion specs
9/6/2006


Bosch video: Micro Hybrid Start Stop System (SES), Mild & Strong Hybrid
Bosch is getting up to speed. They updated their webserver to include hybrid info, explaining the difference between micro hybrid, mild and strong hybrid, including videos, and also established the Bosch Hybrid System Project House in 2004.
9/5/2006

NO MBUSA two-mode hybrid plans


Paul Halata, MBUSA's parting CEO, says MBUSA plans no two mode hybrid within a year after the Chrysler Group's and General Motors hybrid SUVs debut. DaimlerChrysler jointly developed the P1/2 transmission with GM and BMW. MBUSA plans to focus on turbodiesel SUVs instead.
diesel page
8/17/2006



Car motor disappears into the wheels: Siemens VDO eCorner
Siemens engineers are starting to develop their new eCorner concept. The electric motor, brakes, suspension and steering are integrated into the wheel hubs at each corner of the vehicle. The Electronic Wedge Brake (EWB) is part of the eCorner concept and might be first to start series production, around 2010. Previously Richard Schaum at WaveCrest developed a somewhat similar concept, with electric wheel hub motors in a smart coupe. Even earlier the Lohner Porsche Mixte in 1902 featured such a concept.
Siemens VDO press release
Aug 8, 2006


click on pic for schematic
Canter Eco Hybrid goes into production
It's powered by a 3.0 liter four cylinder turbodiesel with 125 hp (92 kW) and a slim 35 kW (48 hp) electric brushless motor in a parallel hybrid configuration, with Li-Ion batteries (346 Volts, 5.5 Ah, 1.9 kWh, 96 cells), and is now shipping in Japan. The Eco Hybrid can be driven by either the diesel engine or the electric motor, or both in parallel and using Mitubishi Fuso's Inomat automated manual transmission. The integrated regenerative braking system produces an additional fuel savings of as much as 20%. Last March Mitsubishi Fuso showed a prototype at the MidAmerica Trucking Show to evaluate interest. Owing to extremely densely populated areas, hybrid vehicles such as the Canter ECO Hybrid play an important role in Japan.
What Van? review of Canter ECO Hybrid
7/6/2006



Bosch and Getrag form hybrid alliance
They plan to integrate dual clutch transmissions and electric drives to provide turnkey solutions to automakers. The picture shows the parallel and torque-split hybrid configurations on the basis of the Getrag 6DCT450 six speed dual clutch transmission for 450 Nm input torque. The parallel hybrid configuration uses one concentric electric motor, while the torque-split hybrid has two.
Bosch press release
Getrag press release
6/8/2006


California's first diesel electric bus goes into service today
56 Clean Air DaimlerChrysler Orion VII low floor buses are to roll out in the fall. San Francisco Muni will own the third largest hybrid fleet in the United States. The buses use the BAE Systems diesel-electric series hybrid HybriDrive based on a 5.9 liter Cummins ULSD turbodiesel and electric traction motor with 250 hp and 320 hp peak. Last fall New York City Transit / MTA Bus ordered a large fleet, Transit Toronto already operates them and in St. Louis the Missouri Metro is testing them.
www.dcbusna.com
SF Muni
6/1/2006

GM, DaimlerChrysler, BMW release some details
about the new two mode hybrids. The electric continously variable transmission (ECVT) has two electric modes and four fixed mechanical ratios. In summary, the four fixed gears overlay two ECVT modes for a total of six operating functions:

  • Input-split ECVT mode, or continuously variable Mode 1, operates from vehicle launch through the second fixed gear ratio.

  • Compound-split ECVT mode, or continuously variable Mode 2, operates after the second fixed gear ratio.

  • First fixed-gear ratio with both electric motors available to boost the internal combustion engine or capture and store energy from regenerative braking, deceleration and coasting.

  • Second fixed-gear ratio with one electric motor available for boost/braking,

  • Third fixed-gear ratio with two electric motors available for boost/braking.

  • Fourth fixed-gear ratio with one electric motor available for boost/braking.

The result, say the three collaborators, is ”trend-setting hybrid technology that provides superior fuel economy, performance and load carrying capability”.

Key Advantages.


When compared to conventional hybrid systems, this avant-garde hybrid technology, relying on both the ECVT modes and the four fixed gear ratios, provides advantages in combined (city and highway) fuel economy, dynamics and towing capability.

Traditional hybrid systems typically have only one torque-splitting arrangement and no fixed mechanical ratios. These systems are often called "one-mode" hybrids. Due to their less capable mechanical content, one-mode hybrids need to transmit a significant amount of power through an electrical path that is 20 percent less efficient than a mechanical path. This requires usually substantial compromise in vehicle capability or reliance on larger electrical motors, which can create cost, weight and packaging issues.

General Motors, DaimlerChrysler and the BMW Group conceive a full hybrid system featuring four fixed mechanical ratios, within the two ECVT modes, to reduce power transmission through the less efficient electrical path. Consequently, the electric motors are more compact and less dependent on engine size.

This combination of two ECVT modes and four fixed gear ratios eliminates the drawbacks of one-mode hybrid systems to allow for efficient operation throughout a vehicle's operating range, at low and high speeds. It also allows for application across a broader variety of vehicles. It is particularly beneficial in demanding applications that require larger engines, such as towing, hill climbing or carrying heavy loads.



Existing internal combustion engines can be used with relatively minimal alteration because the full hybrid system imposes no significant limitation on the size or type of engine. It enables the three automakers to package internal combustion engines with the full hybrid transmissions more cost-effectively and offer the fuel-saving technology across a wider range of vehicles.
4/30/2006






EPRI Journal: "The Plug-In Hybrid Vehicle"
DaimlerChrysler in Mannheim built the Sprinter Plug-In Hybrid Drive vehicles for the test program. "The PHEV is unique. It offers the optimal mix of power from the battery and the engine - of energy from the grid and the gas station to consumers of various transportation needs", says Dr. Fritz Kalhammer, EPRI. Utilitarian Sprinters are often used within the 20 to 30 mile short haul range which may be suitable for PHEV technology.
Read the EPRI article here
Plug-In Hybrid Electric Sprinter Prototype (in pdf)
PHEV Energy Storage System Design (May 2006)
Plug-In Hybrid Development Consortium
Sprinter info page
3/12/2006






NiMH full hybrid battery
Johnson Controls Saft subsidiary Varta has been working on hybrid batteries for the last decade. This is their 270 Volt 1.9 kWh nickel metal hydride battery for full hybrids. It uses forty 7.2 Volt 7.0 Ah modules and includes an energy management controller. For the Sprinter PHEV they supply NiMH or Li-Ion batteries. The Sprinter PHEV NiMH battery comprises 7 times 40 modules with 40 Ah, 14.4 kWh and weighs 364 kg. In electric mode the Sprinter has a range of about 2 miles per kWh.
3/10/2006






Smart Electronic Start/Stop System (SES) for micro hybrids
Bosch starts production of a micro hybrid with SES later this year. The engine stops when standing and starts again with a reversible alternator. Micro hybrids are cost effective, easier to integrate and reduce fuel consumption up to 8%.
Feb 14, 2006

PSA Peugeot Citroлn unveiled diesel-electric hybrid prototype
PSA Peugeot Citroлn unveiled two demonstrators featuring a diesel-electric hybrid powertrain, the Peugeot 307 and the Citroлn C4 Hybride HDi. The performance of these cars represents a major breakthrough in further improving fuel economy and reducing CO2 emissions. They also provide increased driving comfort under all conditions, especially in urban traffic. The main features of the Peugeot 307 prototype are:

  • 1.6 liter 66 kW HDi turbodiesel with EU 4 particulate filter

  • parallel hybrid drive configuration

  • synchronous permanent magnet electric motor rated at 16 kW continuous and up to 23 kW peak

  • new generation stop/start system

  • six speed automated manual gearbox

  • fuel consumption of 3.4 liters per 100 kilometers (NEDC, combined) - 90 g CO2 per kilometer - 69 MPG

  • 240 NiMH battery cells with 288 Volt total

  • all electric driving with up to 50 km/h
    PSA Peugeot Citroлn diesel-electric hybrid
    January 31, 2006

VW starts hybrid cooperation with Continental, ZF, SANYO
Volkwagen ordered a hybrid power control module from Continental Automotive Systems. The EP220 hybrid controller takes 100 kVA CW and 160 kVA peak for up to 60 seconds. Continental also received a specific order for the hybrid drive modules. ZF will supply the electric motor, the clutch and the dual-mass flywheel. SANYO and Volkswagen agreed to codevelop next generation Nickel Metal Hydride HEV battery systems.
January 31, 2006

The BMW Concept X3 EfficientDynamics
Rainer Rump the General Manager Hybrid Cooperation BMW talks us through the innovations that make up the BMW Concept X3 EfficientDynamics.
Vodcast
January 17, 2006

Degussa expands production for lithium-ion electrodes
Degussa expands electrode production for large format lithium-ion batteries at Li-Tech GmbH (SK Firmengruppe) in Kamenz near Dresden. They already cooperate with ENAX at a facility in China.
Jan 13, 2006


"The California HybridMercedes" = Mercedes + Prius
With the sticker single occupant Prius can use car pool lanes. The Prius can't be plugged into the grid like the Sprinter PHEV. Folks are working on an upgrade kit. And it's not a diesel.
CalCar's PHEV

Hybrid sales reach 200,000 in 2005
Hybrid vehicle sales increased to more than 200,000 in 2005 up from 9500 in 2000. In comparison 543,000 diesel vehicles were sold last year in the USA, including E320 CDI, Jeep Liberty, Sprinter van and Dodge RAM.
Dec 15, 2005



Degussa tests Honda Civic IMA hybrid with SEPARION
The battery of a Honda IMA hybrid was updated to Lithium Ion, using the SEPARION ceramic foil supplied by Degussa. SANYO Electric supplies Honda hybrid batteries.
Degussa SEPARION®
Nov 10, 2005






F600 Hygenius introduced in Tokyo
An amazingly advanced fuel cell research F600 was introduced at the Tokyo 2005 auto show with 115 hp (85 kW) and 350 Nm running on fuel cell and Li-Ion battery in hybrid mode. With the new compact fuel cell alone it achieves 82 hp (60 kW) and 250 Nm. It has a 250 mi range and the new high efficiency electric motor is integrated into the rear axle. Mercedes optimistically predicts commercial fuel cell vehicles running on hydrogen for 2012 to 2015. And the son reads Papa Moll. Hybrids are a step towards a future hydrogen highway.
Oct 12, 2005


NYC orders 500 Orion VII diesel electric hybrid buses
After testing diesel electric hybrid buses for several years, New York City Transit, MTA Bus placed a large order with DaimlerChrysler for 500 Orion VII low floor buses equipped with the diesel electric HybriDrive using the 5.9 liter inline 6 Cummins turbodiesel, in a series hybrid configuration, like the Mercedes diesel electric test bus shown in 1969.
BAE HybriDrive
Oct 11, 2005

JESMB Testdrives CLK 500 ISG M273
JESMB drove a CLK 500 ISG Hybrid prototype at the IAA. It has the new M273 E 55 (5.5 liter V8 with 388 hp und 530 NM) V8 and the ISG integrated starter generator hybrid. There is no engine running at the red light but surprisingly the climate system keeps running. It takes only 0.3 seconds to start. Overall the fuel economy is estimated to be around 9-10 liter per 100 km with the ISG saving around 6%.
JESMB
Sep 13, 2005


"DIRECT HYBRID" and "BLUETEC HYBRID" S-Class concept cars
Mercedes showed two concept cars at the IAA 2005 in Frankfurt. The DIRECT HYBRID uses spray-guided direct gasoline injection and an 6 kW/8.2 hp electric motor and a DeNOx catalyst. Fuel consumption drops due to a combination of spray-guided injection and the start/stop mild hybrid. The BLUETEC HYBRID uses a 3.0 liter V6 turbodiesel, the same electric motor and SCR to clean the exhaust. The diesel engine can be run more efficiently with SCR/Adblue reducing consumption in addition to the start/stop system. This mild hybrid captures benefits like start/stop, regenerative braking and torque assist at low engine speeds with comparable low cost.
S350 DIRECT HYBRID    221 kW/300 hp 395 Nm 7.5 sec 0-100 consumption in l/100km: 8.3 instead of 10.2
S320 BLUETEC HYBRID 179 kW/243 hp 575 Nm 7.2 sec 0-100 consumption in l/100km: 7.7 instead of   8.4
Sep 13, 2005


DIESEL BEATS HYBRID: ML320CDI RX400h Coast-to-Coast-Marathon
Autobild tested diesel vs hybrids in a coast to coast marathon. Overall results:
ML320CDI driven 5229 kilometers
RX400h     driven 5126 kilometers
ML320CDI 127.4 gallons fuel
RX400h     139.3 gallons fuel
ML320CDI consumption   9.2 liters/100km (25.5 MPG)
RX400h     consumption 10.3 liters/100km (22.9 MPG)
diesel info page
8/7/2005

Dodge RAM Contractor Special
The RAM diesel HEV comes with a 5.9 liter Cummins turbodiesel with 325 hp / 600 lb-ft, starter/generator, 20-30 kW off-grid power generation capability with 110/220 AC outlets, regenerative braking and better fuel economy. Small scale production started in December 2004 and it's only available to fleet customers.

GMC Tahoe Two-Mode hybrid
This full hybrid employs two electric motors, one for stop and go driving and another one (mode 2) runs at highway speed, improving both city and highway fuel economy by about 25%. The technology is developed with DaimlerChrysler and should come to market in 2007.
2008 GMC Tahoe (estimated)
EPA CITY:   20 MPG instead of 16
HIGHWAY:   25 MPG instead of 20
4/11/2005



GMC Sierra and Chevrolet Silverado RWD hybrid
In this mild hybrid the Continental supplied integrated starter, generator and damper (ISAD) installs between the engine and transmission, thus reducing gas consumption up to 15%, depending on driving cycle. First installed in the 2004 GMC Sierra. The ISAD system was first developed to ease the transition to 42 Volt electrical systems. The later did not become popular, however. Update: Overall 3000 were produced before production ended in December 2006 as the technology was not brought forward to the new platform.
EPA CITY:   18 MPG instead of 16
HIGHWAY:   20 MPG instead of 19
3/1/2005

Ford Escape Hybrid 4WD SUV
Comparing the standard version with 4 cylinder, 4WD and automatic with the hybrid, the fuel economy improves quite a bit in the city and less so on the highway. Conti Teves supplies the regenerative brake (and ESP) system.
EPA CITY:   33 MPG instead of 19
HIGHWAY:   29 MPG instead of 22
2/1/2005

E-class diesel with good highway fuel economy
MBUSA offers the E-class with gas or diesel. The E320 CDI improves the highway and also the city fuel economy of the E320 by more than 30% each while also accelerating faster. Better economy than a hybrid and it's built in Sindelfingen.
EPA CITY:   27 MPG instead of 20
HIGHWAY:   37 MPG instead of 28

Lexus RX400h introduced
It improves the 0-60 by half a second to 7.3 seconds while also increasing the combined fuel ecomony by 33% to 28 MPG (30 MPG CITY, 26 MPG HWY) compared to the RX330 AWD. It's quite complex with three separate electric motors: the NG1 starter generator, the NG2 123 kW motor with permanent magnets and the NGR 50 kW rear axle motor in addition to the 3.3 liter gasoline V6 with 208 hp. Overall it's rated at 268 hp and can add up to 247 lb-ft. at launch on the front axle and 96 lb-ft. on the rear axle. But most owners claim the published numbers are too optimistic obtaining only up to 25 MPG, even in city driving!
EPA CITY:   31 MPG instead of 18
HIGHWAY:   27 MPG instead of 24
2/1/2005



Active M-class transmission
This 7G-Tronic seven speed transmission was shuffed into a corner at the North American International Auto Show 2005 and was not mentioned officially for unknown reasons. It integrates two electric motors with 25 kW (34 hp) each and 147 lb-ft and 221 lb-ft of torque instead of the torque converter and can thus add up to 368 lb-ft or 500 Nm of torque. It's also mated to a four wheel drive transfer case. BMW researches a similar setup.
X5 research car
1/23/2005



S400 diesel-electric hybrid concept with 328 hp (241 kW) introduced
Mercedes showed the S400 diesel-electric Hybrid at the 2005 North American International Auto Show improving both dynamics and efficiency. The P1/2 hybrid transmission replaces the torque converter in the 7G-tronic, combining an efficient 260 hp (191 kW) V8 CDI diesel with two electric motors with a combined 50 kW (68 hp) and a nickel metal hydride battery with a capacity of 1.9 kWh in the trunk. The S400 Hybrid is faster to 100 with 7.6 seconds instead of 7.8 and the fuel economy improves to 34 mpg US (around 7 l/100km), about 15 to 25% better than a standard S400 CDI with 9.6 l/100km. Mercedes engineers promise silky smooth nearly continuous shifting.
1/9/2005

DaimlerChrysler and GM Join Forces to Develop Two-Mode Full Hybrid Propulsion System
The result is expected to be a series of strong hybrid propulsion systems that will serve as a solution for our alternative powertrain needs." MB will focus on high-tech hybrid propulsion systems in passenger cars in the luxury segment. Volkswagen may also be interested in this technology. The first products will be the Dodge Durango and GMC Yukon in 2007 and furtheron this technology will be used in GM, Chrysler and Mercedes vehicles.
Allison Electric Drives (pdf)
12/13/2004



Mercedes to develop gasoline electric hybrid
Mercedes-Benz will bring to market a gasoline electric hybrid with rear wheel drive, designed particularly with the market in Japan and the USA in mind, in areas with much stop-and-go traffic. "It will take less than 5 years and will be a typical Mercedes-Benz premium vehicle", said chief of development Thomas Weber. To save costs, Mercedes is completely open to cooperate with suitable partners and suppliers. Reuters
10/25/2004


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